US4522878A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Material having high mechanical strength and density close to unity, the manufacture and uses thereof
Assignee: IFP Energies nouvelles
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Filing: 1984-03-28
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Granted: 1985-06-11
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Expires: 2004-03-28
Abstract
Abstract A material with high mechanical strength and a density close to 1 is obtained by: (a) dispersing on weight basis 10-15% of a melamine-formol resin, 10-50% of hollow microspheres, and optionally up to 60% of light aggregates, in water; (b) mixing the resultant dispersion in the presence of a cross-linking catalyst, e.g., ammonium chloride, for the melamine-formol resin, until a fluid paste is obtained; and (c) allowing said fluid paste to harden into the desired material.
Inventors
- 👤 Madeleine Martin
- 👤 Jean Lesage
- 👤 Gerard Courbin
- 👤 Alain Rivereau
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 16:15
CPC Classifications
C; C04; C04B; C04B26/00; C04B26/02; C04B26/10; C04B26/12; C04B26/125; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249971; Y10T428/249973; Y10T428/249974; Y10T428/25; Y10T428/254; Y10T428/256; Y10T428/257
Claims Analysis
Total Claims: 15
Claim 1
Independent Claim
183 words
A material with high mechanical strength and a density of about 0.70 to 1.15 g/cm 3 , characterized in that it is obtained by a process which consists essentially of: a step (a), in which a composition consisting essentially of melamine-formaldehyde resin, hollow microspheres having an apparent density of about 200 to 450 kg/m 3 and being other than clay or schist and light aggregates having an apparent density of about 0.75 to 1.1 g/cm 3 and being selected from the group consisting of expanded clay and expanded schist is dispersed in water, the proportions of the constituents used range from 10 to 50% by weight, for the melamine-formaldehyde resin, from 10 to 50% by weight for the hollow microspheres and less than 60% by weight for the light aggregates, a step (b), in which the dispersion thus formed is mixed, in the presence of a cross-linking catalyst for the melamine-formaldehyde resin, until a fluid paste is obtained; a step (c), in which said fluid paste is allowed to harden at a temperature from 5° C. to 60° C. into the desired material.
Claim 2
Dependent Claim
183 words
A material with high mechanical strength and a density of about 0.70 to 1.15 g/cm 3 , characterized in that it is obtained by a process which consists essentially of: a step (a), in which a composition consisting essentially of melamine-formaldehyde resin, hollow microspheres having an apparent density of about 200 to 450 kg/m 3 and being other than clay or schist and light aggregates having an apparent density of about 0.75 to 1.1 g/cm 3 and being selected from the group consisting of expanded clay and expanded schist is dispersed in water, the proportions of the constituents used range from 10 to 50% by weight, for the melamine-formaldehyde resin, from 10 to 50% by weight for the hollow microspheres and less than 60% by weight for the light aggregates, a step (b), in which the dispersion thus formed is mixed, in the presence of a cross-linking catalyst for the melamine-formaldehyde resin, until a fluid paste is obtained; a step (c), in which said fluid paste is allowed to harden at a temperature from 5° C. to 60° C. into the desired material.
Claim 3
Dependent Claim
39 words
The material as claimed in claim 1, wherein the melamine-formaldehyde resin consists of the product of condensation in an alkaline medium of melamine and formaldehyde in proportions of about 3 to 6 moles of formaldehyde per mole of melamine.
Claim 4
Dependent Claim
49 words
The material as claimed in claim 1, wherein the hollow microspheres consists of microballs with a glass or ceramic envelope, or floating spherules obtained by flotation separation from fly-ash collected from the smoke of boilers using pulverized coal, and they have a granulometry of about 20 to 200 μm.
Claim 5
Dependent Claim
24 words
The material as claimed in claim 1, wherein the water represents 10 to 30% by weight with respect to the weight of said constituents.
Claim 6
Dependent Claim
63 words
The material as claimed in claim 1, wherein the proportions of constituents used are from 15 to 40% by weight for the melamine-formaldehyde resin, from 15 to 40% by weight for the hollow microspheres and from 25 to 60% by weight for the light aggregates and the water represents from 10 to 25% by weight with respect to the weight of said constituents.
Claim 7
Dependent Claim
19 words
The material as claimed in claim 1, wherein the cross-linking catalyst is ammonium chloride, tartaric acid or aqueous ammonia.
Claim 8
Dependent Claim
27 words
The material as claimed in claim 1, wherein the cross-linking catalyst is used in a proportion of 1 to 3% by weight with respect to the resin.
Claim 9
Dependent Claim
20 words
Article according to claim 10, wherein said articles are coated with a sealing coating made from a reinforced plastic material.
Claim 10
Dependent Claim
20 words
The material as claimed in claim 1, wherein the proportion of the light aggregate is 25 to 60% by weight.
Claim 11
Dependent Claim
14 words
Articles of manufacture suitable for marine application composed of the material of claim 1.
Claim 12
Dependent Claim
12 words
An article according to claim 10, in the form of a tube.
Claim 13
Dependent Claim
17 words
A tube according to claim 11, coated with a sealing coating made from a reinforced plastic material.
Claim 14
Dependent Claim
18 words
A tube according to claim 12, wherein the reinforced plastic material is an epoxy resin glass fiber system.
Claim 15
Dependent Claim
31 words
A material according to claim 1 having a compressive strength of 18.5 to 30 MPa and a bending strength of 3.5 to 5 MPA measured after 28 days at 20° C.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-06-10 | 1988-12-10 | 1989-06-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-06-10 | 1992-12-10 | 1993-06-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-06-10 | 1996-12-10 | 1997-06-11 | $7700.00 | Window Closed / Lapsed |